Subject: IMT-99: Production Planning and Control-MT1
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PART-A

1. What is production planning? What are its objectives and scope.

2. What are the various production systems? Describe the characteristics, merits and demerits of each system.

3. There are two methods of processing oil at a refinery. Method 1 has fixed costs of Rs. 9,00,000 whereas the fixed cost for Method 2 are 11,00,000. The variable costs depend on the chemicals used and heating requirements. These are Rs. 1.50 and Rs. 1.00 per barrel respectively. Which method is more economical?

4. What is aggregation production plan? Discuss the pure strategies and the mixed strategy in aggregate planning.

5. Write short notes on :-

     (a) Flexible Manufacturing System.

     (b) Acceptance Sampling Techniques.

     (c) Capacity Planning.

PART-B

1. What is production planning and control. Discuss it's objectives and scope.

2. What do you understand by product layout and process layout ? Compare the advantages and disadvantages of these layouts.

3. (a) Explain the methodology and assumptions for sequencing 'n' jobs through three machines A, B and C in prescribed order ABC for each job.

     (b) There are seven jobs to be processed through three machines M1, M2 and M3 in that order. The processing time for each job in hours is given in the table. Sequence these jobs using Johnson's method and find the overall processing time and idle times for the three machines :-


Job

M1

M2

M3

A

1

7

8

B

3

3

10

C

7

8

9

D

9

2

11

E

4

8

9

F

5

6

14

G

2

1

12

4. Differentiate the following :-

     (a) Flow shop vs job shop characteristics.

     (b) Make-to-stock vs Make-to-order.

     (c) Aggregate planning & Master Production Schedule

5. Alpha Electronic Company produces 2000 TV sets in a year for which it needs an equal number of tubes of certain type. Each tube costs Rs. 10/- and the cost to hold a tube in stock for a year is Rs. 2.40 / unit / annum. Besides, the cost of placing an order is Rs. 150/- per order. The number of working days in the company is 250 and the lead time is 15 working days. Determine :-

     (a) Economic Order Quantity.

     (b) Re-order level.

     (c) Annual total variable cost.

     (d) Inventory cycle time.

     (e) Monetary value of optimal order quantity.

     (f) Rupee value of average inventory.

PART-A

1. What is JIT? Discuss it's benefits.

2. What is Total Quality Management? Discuss AOQL.

3. Explain variable and attributes control charts.

4. What is Value Engineering? Discuss the various steps involved in it.

5. A small project consists of eight activities and has following characteristics:-

Activity

Preceding

Time Estimate (in weeks)

Activity

Most optimistic (to)

Most likely M

Most pessimistic (tp)

A

-

2

6

12

B

-

10

12

26

C

A

8

9

10

D

A

10

15

20

E

A

7

7.5

11

F

B,C

9

9

9

G

D

3

3.5

7

H

E,F,G

5

5

5

     (i) Draw the network and determine the critical path.

(ii) Find the float for all the activities.

(iii) If a 30 week deadline is imposed, what is the probability that the project will be completed on time?

(iv) If the project manager wants to be 99% sure that the project will be completed on the scheduled date, how many weeks before that date should he start the project work?


CASE STUDY - 1

An electric company manufactures both ceiling and table fans. Resource requirements for both these items are indicated

below :-

Product Type

Labour Hour per Unit

Raw Material per Unit (kg)

Profit per Unit (Rs)

Table Fan

2

8

80

Ceiling Fan

4

6

100

The company can make available 80 hours of labour and 240 kgs of raw materials. How many table and ceiling fans should be produced in a day to maximise profit? Solve the problem using linear graph and ISO - profitlines.

CASE STUDY - 2

Jaycee Industries manufactures Radios. The company wishes to make approximately 290 radios per day. The following table

lists all basic tasks performed along the assembly line.

Task

Operation Time (min)

Immediate Preceding

Tasks

A

0.20

-

B

0.30

A

C

0.40

A

D

0.60

B,C

E

0.80

-

F

0.80

E

G

0.60

D,E

H

1.20

F,G

I

1.20

H

J

1.00

I

K

1.90

J

Total

9.00

The shop operates five days per week and two shifts per day. The company provides two coffee breaks of ten minutes each during an eight hour day.

     (a) Group the activities into the most efficient arrangement.

     (b) What is the cycle time of your arrangement?

     (c) What is the balance delay and percentage?